Sound attenuation module and oversized grill

ABSTRACT

A Sound Attenuation Module and Oversized Grill is disclosed which prevents noise generated by an HVAC system from traveling through the duct system and into the room to which the air is directed. The goal is accomplished by use of oversized duct grills and an module placed between the wall and HVAC System, and uses an enclosure designed to expand the distance that the noise must travel.

TECHNICAL FIELD OF THE DISCLOSURE

The present disclosure relates generally to the field of air conditioning and ducting.

BACKGROUND OF THE DISCLOSURE

Heating, ventilation, and air conditioning (HVAC) systems have moving parts that cause noise that is bothersome to those in the rooms which receive treated air.

The HVAC industry has struggled with the balance of desired attributes in such systems; a system that moves air more quickly necessarily creates more noise than one that moves air more slowly. This is not due solely to the fan, but to other moving parts as well, include motors, compressors, vibration of metal parts, and even refrigerant flow.

One of the solutions that the HVAC industry uses to lessen the noise caused in a space receiving treated air includes simply increasing the distance from the moving parts to the air-conditioned space. Use of this approach requires distance, and is difficult to employ in a wall-mount unit that is often used in temporary buildings. This approach also requires substantial labor, as routing a longer path duct between the blower or fan outlet to the desired location becomes a task requiring an expensive skilled and experienced worker in the field.

As conditions change over time in temporary buildings, the equipment used in an HVAC system must change. Many conditions can trigger these changes, including a need to condition the air in a higher volume of, or new government regulations require a change in a system's components, or a failed system has to be replaced. In these situations, industry vendors and service personnel need parts that are backwards compatible with the existing building structure as much as possible.

The construction industry needs an apparatus that allows for sound attenuation of an HVAC system, and easy retrofitting of that system into existing products and systems.

SUMMARY OF THE DISCLOSURE

The present disclosure includes a Sound Attenuation Module and Oversized Grill used to reduce the sound of an HVAC system by adding an apparatus to add distance between the fan and the space, without elongating the physical system unduly, while also allowing for a retro-fit installation.

Other features and advantages of the present disclosure will be apparent to those of ordinary skill in the art upon reference to the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the disclosure, and to show by way of example how the same may be carried into effect, reference is now made to the detailed description of the disclosure along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts in one embodiment of the invention, as follows:

FIG. 1 is a front view of the mounted Oversized Grill 100 with Mounting Structure 200.

FIG. 2 is a side sectional view of the mounted Oversized Grill 100 with Grill Mounting Mechanism 200, as shown in FIG. 1 along section lines B-B.

FIG. 3 is a front view of the mounted Oversized Grill 100 without a Grill Mounting Mechanism 200.

FIG. 4 is a side sectional view of the mounted Oversized Grill 100 without a Grill Mounting Mechanism, as shown in FIG. 3 and along section lines A-A.

FIG. 5 is a front view of an air conditioner unit and Sound Attenuation Module (SAM) 500 combination. (The SAM is not visible in this view.)

FIG. 6 is a side sectional view of an air conditioner unit and SAM 500 combination, as shown in FIG. 5, along section lines A-A.

FIG. 7 shows a side view of a Sound Attenuation Module 500.

FIG. 8 shows a top view of the Sound Attenuation Module 500 as provided in FIG. 7.

FIG. 9 shows a front view of a Sound Attenuation Module 500 as depicted in FIGS. 7 and 8.

FIG. 10 shows a side sectional view of the Sound Attenuation Module 500 as shown in FIGS. 7-9 along section lines C-C.

FIG. 11 shows a front view of one embodiment of an indoor embodiment of the Sound Attenuation Module 500.

FIG. 12 shows a sectional view of the embodiment of the Sound Attenuation 500 as shown in FIG. 11.

FIG. 13 shows a front view of an outdoor-mounted HVAC System 600 with built-in SAM 500.

FIG. 14 shows a sectional view of the outdoor-mounted HVAC System 600 with built-in SAM 500, as shown in FIG. 13, along section lines A-A.

FIG. 15 shows a sectional view of a generic single-path Sound Attenuation Module (“Half-SAM”) combined with an Oversized Grill.

FIG. 16 shows a top view of a 90-SAM.

DETAILED DESCRIPTION OF THE DISCLOSURE

While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The disclosure is primarily described and illustrated hereinafter in conjunction with various embodiments of an HVAC system comprising a Sound Attenuation Module 500 and Oversized Grill 100. The specific embodiment discussed herein is, however, merely illustrative of specific ways to make and use the disclosure and do not limit the scope of the disclosure to the specific context disclosed.

FIG. 1 shows an Oversized Grill 100 that is set off from the surrounding Wall Foundation 300 by a Grill Mounting Mechanism 200, through which supply air exits though a Mounting Structure 110 through Louvers 110. In typical use, grills are mounted as flush as possible to walls in effort to make them less visible, but this invention benefits from a larger grill that extends from the wall on the so that an Oversized Grill 100 can be used. In the FIG. 1 embodiment, Louvers 110 are mounted flush to a section of wall that has been built out from the wall with a larger opening for larger Louvers 110 than would otherwise be used.

FIG. 2 shows a cross-sectional view of the embodiment of the invention shown in FIG. 1 along the B-B section lines.

In using an Oversized Grill 100 instead of the typical grill that merely covers the Return Opening 630, the flow of air has a larger area in the Louvers 110 through which to travel. This increased area through the Louvers 110 creates less sound than would be created if the Louvers 110 were smaller.

FIG. 3 and FIG. 4 depicts a second embodiment of the installed device. This embodiment differs from that shown on FIG. 1 and FIG. 2 by mounting the Oversized Grill 100 directly on the Foundational Wall 300, avoiding the use of a Grill-Mounting Mechanism 200. In this construction, the Louvers 110 are embedded in a frame that connects directly to the Wall Foundation 300.

In the embodiment shown in FIG. 5, a typical HVAC system is shown as installed on a commercial building, including an HVAC System 600 mounted with Sound Attenuation Module 500 between the HVAC system and the exterior Wall 300. This view shows the inobvious appearance of the unit, not noticeable as distinct from the HVAC System 600 to the casual viewer.

FIG. 6 is a side sectional view of an HVAC System 600 with installed Sound Attenuation Module (SAM) 500 between the HVAC System 600 and exterior Wall 300. This view shows the flow of air through the system, starting the Return Air 620 (so called because it is returning to the HVAC system 600) going through the Return Opening 630, then the air is diverted by a panel of Attenuation Panel 660 (which can be constructed of any number of materials, preferably sound absorbent), then into the HVAC System 600 where the air is conditioned, and then back out of the system through the upper pathway of the SAM 500 after a second diverting Attenuation Panel 660, and through the Supply Opening 650 to become Supply Air 610 which is conditioned for human comfort in the space on the interior side of the Wall 300. Though the Attenuation Panel 660 is shown to extend across the entire width of the duct in this embodiment, other embodiments allow for different shapes, including the Panels 660 to include a slots at the sides of the Panels 660 so they do not attach to the side of the ducts, or alternative vertical or horizontal slots. One of the important aspects of the invention is that Attenuation Panels 660 are placed in the SAM 500 to reduce sound from the HVAC system into the air-conditioned room.

FIG. 7 is a side view of the SAM 500, showing placement of the Attenuation Panels 660 and the openings in the SAM 500 through with the air flows, including the lower return path constituting the Return Opening 630, Attenuation Panel 660 and out through HVAC Return 635, and then the upper supply path constituted by the HVAC Supply 655, a second Attenuation Panel 660 and out through the Supply Opening 650.

FIG. 8 is a top view of the SAM 500, showing the central location of the Attenuation Panels 660.

FIG. 9 is a front view of the uninstalled SAM 500, showing the openings of the device, and the lower edge of the diverting Attenuation Panels 660.

FIG. 10 shows a cross-sectional view of the embodiment in FIG. 9, similar to FIG. 7.

The disclosure thus far has detailed an interior SAM 500 installed on the exterior wall, and to which an HVAC System 600 is installed. However, the SAM 500 can be installed on the interior of an air-conditioned room as shown in FIG. 11 and FIG. 12. In practice, this may be an effective method of retrofitting a building with the SAM 500.

Finally, the SAM 500 and HVAC System 600 may be constructed as one combined piece, as shown in FIGS. 13 and 14. FIG. 13 shows a front view of an outdoor-mounted Combination SAM-HVAC 750, without the details of ducting. FIG. 14 shows the cross-sectional view defined by A-A in FIG. 13.

The SAM 500 is built so that an already installed HVAC System can be retrofit. Though the drawings reflect a particular build, it is considered within the art to construct similar designs which match up with the inlet and outlet openings of various systems to enable an easy, ductless interjection between the Wall 300 and HVAC System 600.

FIG. 15 shows a Half-SAM 800 in which the module has only one internal extended air path with an Attenuation Panel 660 in either the supply or receive air path, depending on space or other design constraints. Use of the Oversized Grill 100 is shown on this embodiment in the Return Opening 630, but it could also be installed on the Supply Opening 650. The noise generated by air flow in a path can be attenuated by use of the Oversized Grill 100, so an HVAC System 600 might employ both the Oversized Grill 110 and one or both elongated air pathways created by a full-sized SAM 500 or on a Half-SAM 800.

It is assumed that an individual experienced in the art could modify the embodiments disclosed in this application to fit a number of needs that are variations of the embodiments disclosed. For example, the disclosed embodiments discuss SAMs which fit sandwiched between an external wall and HVAC system, but one in the art could easily construct a 90-Degree SAM 850 that turns the air ducting 90 degrees to one side, so that the HVAC System 600 is turned 90 degrees, placing one side of the HVAC System 600 against the exterior Wall 300, as seen in the top view of FIG. 16. Many other similar arrangements embodying the invention are available to those in the art.

LEGEND to drawings and items referenced:

-   100 Oversized Grill -   110 Louvers -   200 Grill Mounting Mechanism -   300 Wall Foundation -   310 Wall Opening -   500 SAM -   600 HVAC system -   610 Supply Air -   620 Return Air -   630 Return Opening -   635 HVAC Return -   640 Supply open -   650 Supply Opening -   655 HVAC Supply -   660 Attenuation Panel -   700 Floor -   750 Combination SAM-HVAC System -   800 Half-SAM -   850 90-Degree SAM 

What is claimed is:
 1. A method of attenuating noise generated by an HVAC system, comprising: a) choosing an HVAC system to be mounted on the exterior wall of a building; b) creating holes in that same exterior wall between the interior of a building and the exterior of the building which match the hole and duct pattern of the chosen HVAC system; c) mounting a Sound Attenuation Module (“SAM”, an enclosed box on the exterior side of the wall, said SAM equipped with: i) a hole pattern on one side of the box that match the holes previously constructed in the exterior wall and the HVAC system; ii) an additional hole pattern matching the same holes on the opposite side of the box; iii) two air ducts constructed within the box which connect matching holes on either side of the box that creates a physically longer air duct in at least one of the connected pathways; d) mounting the HVAC system to the SAM.
 2. The method of attenuating noise generated by an HVAC system as described in claim 1, with the additional component in the SAM of Attenuating Panels, which are placed in the ducting within the SAM.
 3. An apparatus to attenuate noise generated by an HVAC system, comprising: a) an enclosure with two matching external hole pattern on two sides of the enclosure which also match the duct connection holes of an HVAC system; b) ducts within the enclosure which connect the matching holes that constitute the hole pattern previously identified; c) where at least one interior duct connecting two of the matching holes leading to the enclosure's exterior duct openings are physically constructed to be deliberately longer than is necessary.
 4. An apparatus as in claim 3, in which the enclosure is shaped like a rectangular prism.
 5. An apparatus as in claim 4, in which the external duct holes are on opposing sides of the enclosure rectangular prism.
 6. An apparatus as in claim 3, in which the two pairs of external duct holes are constructed on two adjacent side.
 7. An apparatus as in claim 3, in which sound attenuating panels or material are installed within the ducts to both assist diversion of the air in a desired direction within the duct, and to absorb sound.
 8. An Oversized Grill designed to cover an air duct, comprising an oversized duct grill and louvers, and an installation mechanism which deliberately holds the grill out from the wall.
 9. An Oversized Grill as in claim 8 in which the Louvers is installed and held in place by an extension from the wall that is made of such material as wood and sheetrock.
 10. An Oversized Grill as in claim 8, in which the Louvers are framed, and that frame is sufficiently large that it covers the open duct without substantial other materials.
 11. An apparatus as in claim 3, in which the Sound Attenuation Module is installed on the exterior of an exterior wall.
 12. An apparatus as in claim 3, in which the Sound Attenuation Module is installed inside a room to be continued. 